System and method for downhole operation using pressure activated valve and sliding sleeve

ABSTRACT

An isolation system for producing oil and gas from one or more formation zones and methods of use are provided comprising one or more pressure activated valve and one or more tool shiftable valve. The tool shiftable valve may be actuated before or after actuation of the pressure activated valve.

This application is a continuation of application Ser. No. 10/004,956,filed Dec. 5, 2001, now U.S. Pat. No. 6,722,440, which claims thebenefit of U.S. Provisional Application Ser. No. 60/251,293, filed Dec.5, 2000. U.S. Pat. No. 6,722,440 is also a continuation-in-part of U.S.application Ser. No. 09/378,384, filed on Aug. 20, 1999, now U.S. Pat.No. 6,347,949, which claims the benefit of U.S. Provisional ApplicationSer. No. 60/097,449, filed on Aug. 21, 1998.

BACKGROUND OF THE INVENTION

The present invention relates to the field of well completion assembliesfor use in a wellbore. More particularly, the invention provides amethod and apparatus for completing and producing from multiple mineralproduction zones, independently or in any combination.

The need to drain multiple-zone reservoirs with marginal economics usinga single well bore has driven new downhole tool technology. While manyreservoirs have excellent production potential, they cannot support theeconomic burden of an expensive deepwater infrastructure. Operatorsneeded to drill, complete and tieback subsea completions to centralproduction facilities and remotely monitor, produce and manage thedrainage of multiple horizons. This requires rig mobilization (with itsassociated costs running into millions of dollars) to shut off orprepare to produce additional zones from the central productionfacility.

Another problem with existing technology is its inability to completetwo or more zones in a single well while addressing fluid loss controlto the upper zone when running the well completion hardware. In thepast, expensive and often undependable chemical fluid loss pills werespotted to control fluid losses into the reservoir after perforatingand/or sand control treatments. A concern with this method whencompleting upper zones is the inability to effectively remove thesepills, negatively affecting the formation and production potential andreducing production efficiency. Still another problem is economicallycompleting and producing from different production zones at differentstages in a process, and in differing combinations. The existingtechnology dictates an inflexible order of process steps for completionand production.

Prior systems required the use of a service string, wire line, coiltubing, or other implement to control the configuration of isolationvalves. Utilization of such systems involves positioning of toolsdown-hole. Certain disadvantages have been identified with the systemsof the prior art. For example, prior conventional isolation systems havehad to be installed after the gravel pack, thus requiring greater timeand extra trips to install the isolation assemblies. Also, prior systemshave involved the use of fluid loss control pills after gravel packinstallation, and have required the use of through-tubing perforation ormechanical opening of a wire-line sliding sleeve to access alternate orprimary producing zones. In addition, the installation of prior systemswithin the wellbore require more time consuming methods with lessflexibility and reliability than a system which is installed at thesurface. Each trip into the wellbore adds additional expense to the wellowner and increases the possibility that tools may become lost in thewellbore requiring still further operations for their retrieval.

While pressure actuated valves have been used in certain situations,disadvantages have been identified with such devices. For example, priorpressure actuated valves had only a closed position and an openposition. Thus, systems could not reliably use more than one such valve,since the pressure differential utilized to shift the first valve fromthe closed position to the open would be lost once the first valve wasopened. Therefore, there could be no assurance all valves in a systemwould open.

There has therefore remained a need for an isolation system for wellcontrol purposes and for wellbore fluid loss control, which combinessimplicity, reliability, safety and economy, while also affordingflexibility in use.

SUMMARY OF THE INVENTION

The present invention provides a system which allows an operator to,perforate, complete, and produce multiple production zones from a singlewell in a variety of ways allowing flexibility in the order ofoperation. An isolation system of the present invention does not requiretools to shift the valve and allows the use of multiple pressureactuated valves in a production assembly.

According to one aspect of the invention, after a zone is completed,total mechanical fluid loss is maintained and the pressure-actuatedcirculating (PAC) and/or pressure-actuated device (PAD) valves areopened with pressure from the surface when ready for production. Thiseliminates the need to rely on damaging and sometimes non-reliable fluidloss pills being spotted in order to control fluid loss after the fracor gravel pack on an upper zone (during the extended time process ofinstalling completion production hardware).

According to another aspect of the present invention, the economical andreliable exploitation of deepwater production horizons that werepreviously not feasible are within operational limits of a system of theinvention.

A further aspect of the invention provides an isolation sleeve assemblywhich may be installed inside a production screen and thereaftercontrolled by generating a pressure differential between the valveinterior and exterior.

According to a still another aspect of the invention, there is provideda string for completing a well, the string comprising: a base pipecomprising a hole; at least one packer in mechanical communication withthe base pipe; at least one screen in mechanical communication with thebase pipe, wherein the at least one screen is proximate the hole in thebase pipe; an isolation pipe concentric within the base pipe andproximate to the hole in the base pipe, wherein an annulus is definedbetween the base pipe and the isolation pipe, and an annulus-to-annulusvalve in mechanical communication with the base pipe and the isolationpipe.

Another aspect of the invention provides a system for completing a well,the system comprising: a first string comprising: a first base pipecomprising a hole, at least one first packer in mechanical communicationwith the first base pipe, at least one first screen in mechanicalcommunication with the first base pipe, wherein the at least one firstscreen is proximate the hole in the first base pipe, a first isolationpipe concentric within the first base pipe and proximate to the hole inthe first base pipe, wherein a first annulus is defined between thefirst base pipe and the first isolation pipe, and a firstannulus-to-annulus valve in mechanical communication with the first basepipe and the first isolation pipe; and a second string which isstingable into the first string, the second string comprising: a secondbase pipe comprising a hole, at least one second screen in mechanicalcommunication with the second base pipe, wherein the at least one secondscreen is proximate the hole in the second base pipe, a second isolationpipe concentric within the second base pipe and proximate to the hole inthe second base pipe, wherein a second annulus is defined between thesecond base pipe and the second isolation pipe, and a secondannulus-to-annulus valve in mechanical communication with the secondbase pipe and the second isolation pipe.

According to an aspect of the invention, there is provided a system forcompleting a well, the system comprising: a first string comprising: afirst base pipe comprising a hole, at least one first packer inmechanical communication with the first base pipe, at least one firstscreen in mechanical communication with the first base pipe, wherein theat least one first screen is proximate the hole in the first base pipe,a first isolation pipe concentric within the first base pipe andproximate to the hole in the first base pipe, wherein a first annulus isdefined between the first base pipe and the first isolation pipe, and afirst annulus-to-annulus valve in mechanical communication with thefirst base pipe and the first isolation pipe; and a second string whichis stingable into the first string, the second string comprising: asecond base pipe comprising a hole, at least one second screen inmechanical communication with the second base pipe, wherein the at leastone second screen is proximate the hole in the second base pipe, asecond isolation pipe concentric within the second base pipe andproximate to the hole in the second base pipe, wherein a second annulusis defined between the second base pipe and the second isolation pipe,and a second annulus-to-annulus valve in mechanical communication withthe second base pipe and the second isolation pipe; and a third stringwhich is stingable into the second string, the third string comprising:a third base pipe comprising a hole, at least one third screen inmechanical communication with the third base pipe, wherein the at leastone third screen is proximate the hole in the third base pipe, a thirdisolation pipe concentric within the third base pipe and proximate tothe hole in the third base pipe, wherein a third annulus is definedbetween the third base pipe and the third isolation pipe, and a thirdannulus-to-annulus valve in mechanical communication with the third basepipe and the third isolation pipe.

According to a further aspect of the invention, there is provided amethod for completing multiple zones, the method comprising: setting afirst string in a well proximate a first production zone, wherein thefirst string comprises: a first base pipe comprising a hole, at leastone first packer in mechanical communication with the first base pipe,at least one first screen in mechanical communication with the firstbase pipe, wherein the at least one first screen is proximate the holein the first base pipe, a first isolation pipe concentric within thefirst base pipe and proximate to the hole in the first base pipe,wherein a first annulus is defined between the first base pipe and thefirst isolation pipe, and a first annulus-to-annulus valve in mechanicalcommunication with the first base pipe and the first isolation pipe:performing at least one completion operation through the first string,isolating the first production zone with the first string; and producingfluids from the first production zone.

According to a further aspect of the invention, there is provided amethod for completing multiple zones, the method comprising: setting afirst string in a well proximate a first production zone, wherein thefirst string comprises: a first base pipe comprising a hole, at leastone first packer in mechanical communication with the first base pipe,at least one first screen in mechanical communication with the firstbase pipe, wherein the at least one first screen is proximate the holein the first base pipe, a first isolation pipe concentric within thefirst base pipe and proximate to the hole in the first base pipe,wherein a first annulus is defined between the first base pipe and thefirst isolation pipe, and a first annulus-to-annulus valve in mechanicalcommunication with the first base pipe and the first isolation pipe;performing at least one completion operation through the first string;isolating the first production zone with the first string; and producingfluids from the first production zone; stinging a second string into thefirst string and setting the second string proximate a second productionzone, wherein the second string comprises: a second base pipe comprisinga hole, at least one second screen in mechanical communication with thesecond base pipe, wherein the at least one second screen is proximatethe hole in the second base pipe, a second isolation pipe concentricwithin the second base pipe and proximate to the hole in the second basepipe, wherein a second annulus is defined between the second base pipeand the second isolation pipe, and a second annulus-to-annulus valve inmechanical communication with the second base pipe and the secondisolation pipe; performing at least one completion operation through thesecond string; and producing fluids from the second production zonethrough the second string.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is better understood by reading the followingdescription of non-limitative embodiments with reference to the attacheddrawings wherein like parts in each of the several figures areidentified by the same reference characters, and which are brieflydescribed as follows.

FIGS. 1A through 1I illustrate a cross-sectional, side view of first andsecond isolation strings.

FIGS. 2A through 2L illustrate a cross-sectional, side view of first,second and third isolation strings, wherein the first and second stringsco-mingle production fluids.

FIGS. 3A through 3K illustrate a cross-sectional, side view of first,second and third isolation strings, wherein the second and third stringsco-mingle production fluids.

FIGS. 4A through 4N illustrate a cross-sectional, side view of first,second, third and fourth isolation strings, wherein the first and secondstrings co-mingle production fluids and the third and fourth stringsco-mingle production fluids.

FIGS. 5A through 5B are a cross-sectional side view of a pressureactuated device (PAD) valve shown in an open configuration.

FIGS. 6A through 6E are a cross-sectional side view of the PAD valve ofFIG. 5A through 5F, shown in a closed configuration so as to restrictflow through the annulus.

FIGS. 7A through 7D are a side, partial cross-sectional, diagrammaticview of a pressure actuated circulating (PAC) valve assembly in alocked-closed configuration. It will be understood that thecross-sectional view of the other half of the production tubing assemblyis a mirror image taken along the longitudinal axis.

FIGS. 8A through 8D illustrate the isolation system of FIG. 7 in anunlocked-closed configuration.

FIGS. 9A through 9D illustrate the isolation system of FIG. 8 in an openconfiguration.

FIG. 10 is a cross-sectional, diagrammatic view taken along line A—A ofFIG. 9C showing the full assembly.

FIGS. 11A through 11D illustrate a cross-sectional side view of a firstisolation spring.

FIGS. 12A through 12I illustrate a cross-sectional side view of a secondisolation string stung into the first isolation string shown in FIG. 11.

FIGS. 13A through 13L illustrate a cross-sectional side view of a thirdisolation string stung into the second isolation string shown in FIG.12, wherein the first isolation string is also shown.

FIGS. 14A through 14L illustrate a cross-sectional side view of thefirst, second and third isolation strings shown in FIGS. 11 through 13,wherein a production string is stung into the third isolation string.

It is to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, as the invention may admit to otherequally effective embodiments.

DETAILED DESCRIPTION OF THE INVENTION

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiment illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, such alterations and furthermodifications in the illustrated device, and such further applicationsof the principles of the invention as illustrated therein beingcontemplated as would normally occur to one skilled in the art to whichthe invention relates.

Referring to FIGS. 1A through 1I, there is shown a system for productionover two separate zones. A first isolation string 11 is placed adjacentthe first production zone 1. A second isolation string 22 extends acrossthe second production zone 2. The first isolation string 11 enablesgravel pack, fracture and isolation procedures to be performed on thefirst production zone 1 before the second isolation string 22 is placedin the well. After the first production zone 1 is isolated, the secondisolation string 22 is stung into the first isolation string 11. Withoutrunning any tools on wire line or coil tubing to manipulate any of thevalves, the second isolation string 22 enables gravel pack, fracture andisolation of the second production zone 2. The first and secondisolation strings 11 and 22 operate together to allow simultaneousproduction of zones 1 and 2 without co-mingling the production fluids.The first production zone 1 produces fluid through the interior of theproduction pipe or tubing 5 while the second production zone 2 producesfluid through the annulus between the production tubing 5 and the wellcasing (not shown).

The first isolation string 11 comprises a production screen 15 which isconcentric about a base pipe 16. At the lower end of the base pipe 16there is a lower packer 10 for engaging the first isolation string 11 inthe well casing (not shown). Within the base pipe 16, there is aisolation or wash pipe 17 which has an isolation valve 18 therein. Apressure-actuated device (PAD) valve 12 is attached to the tops of boththe base pipe 16 and the isolation pipe 17. The PAD valve 12 allowsfluid communication through the annuluses above and below the PAD valve.A pressure-actuated circulating (PAC) valve 13 is connected to the topof the PAD valve 12. The PAC valve allows fluid communication betweenthe annulus and the center of the string. Further, an upper packer 19 isattached to the exterior of the PAD valve 12 through a further sectionof base pipe 16. This section of base pipe 16 has a cross-over valve 21which is used to communicate fluid between the inside and outside of thebase pipe 16 during completion operations.

Once the first isolation string 11 is set in the well casing (not shown)by engaging the upper and lower packers 19 and 10, fracture and gravelpack operations are conducted or may be conducted on the firstproduction zone. To perform a gravel pack operation, a production tube(not shown) is stung into the top of a sub 14 attached to the top of thePAC valve 13. Upon completion of the gravel pack operation, theisolation valve 18 and the PAD valve 12 are closed to isolate the firstproduction zone 1. The tubing is then withdrawn from the sub 14. Thesecond isolation string 22 is then stung into the first isolation string11. The second isolation string comprises a isolation pipe 27 whichstings all the way into the sub 14 of the first isolation string 11. Thesecond isolation string 22 also comprises a base pipe 26 which stingsinto the upper packer 19 of the first isolation string 11. The secondisolation string 22 also comprises a production screen 25 which isconcentric about the base pipe 26. A PAD valve 23 is connected to thetops of the base pipe 26 and isolation pipe 27. The isolation pipe 27also comprises isolation valve 28. Attached to the top of the PAD valve23 is a sub 30 and an upper packer 29 which is connected through asection of pipe. Production tubing 5 is shown stung into the sub 30. Thesection of base pipe 26 between the packer 29 and the PAD valve 23 alsocomprises a cross-over valve 31.

Since the second isolation string 22 stings into the upper packer 19 ofthe first isolation string 11, it has no need for a lower packer.Further, since the first isolation string 11 has been gravel packed andisolated, the second production zone 2 may be fractured and gravelpacked independent of the first production zone 1. As soon as thecompletion procedures are terminated, the isolation valves 28 and thePAD valve 23 are closed to isolate the second production zone 2.

The production tubing 5 is then stung into the sub 30 for productionfrom either or both of zones 1 or 2. For example, production from zone 1may be accomplished simply by opening isolation valve 18 and allowingproduction fluid from zone 1 to flow through the center of the system upthrough the inside of production tubing 5. Alternatively, productionfrom only zone 2 may be accomplished by opening isolation valve 28 tosimilarly allow production fluids from zone 2 to flow up through theinside of production tubing 5.

Non-commingled simultaneous production is accomplished by closingisolation valve 18 and opening PAD valve 12 and PAC valve 13 to allowzone 1 production fluids to flow to the inside of the system and upthrough the center of production tubing 5. At the same time, PAD valve23 may be opened to allow production fluids from zone 2 to flow throughthe annulus between production tubing 5 and the casing.

The first isolation string 11 comprises a PAD valve 12 and a PAC valve13. The second isolation string 22 comprises a PAD valve 23 but does notcomprise a PAC valve. PAD valves enable fluid production through theannulus formed on the outside of a production tube. PAC valves enablefluid production through the interior of a production tube. These valvesare discussed in greater detail below.

Referring to FIGS. 2A through 2L, an isolation system is showncomprising three separate isolation strings. In this embodiment of theinvention, the first production string 11 comprises a lower packer 10and a base pipe 16 which is connected to the lower packer 10. Aproduction screen 15 is concentric about the base pipe 16. A isolationpipe 17 extends through the interior of the base pipe and has anisolation valve 18 thereon. The PAD valve 12 of the first isolationstring is attached to the tops of the base pipe 16 and isolation pipe17. In this embodiment of the invention, a sub 14 is attached to the topof the PAD valve 12. The first isolation string 11 also comprises anupper packer 19 which is connected to the top of the PAD valve 12through a length of base pipe 16. The length of base pipe 16 has thereina cross-over valve 21.

The second isolation string 22 is stung into the first isolation string11 and comprises a base pipe 26 with a production screen 25 therearound.Within the base pipe 26, there is a isolation pipe 27 which is stunginto the sub 14 of the first isolation string 11. The isolation pipe 27comprises isolation valve 28. Further, the base pipe 26 is stung intothe packer 19 of the first isolation string 11. The second isolationstring 22 comprises a PAD valve 23 which is attached to the tops of thebase pipe 26 and isolation pipe 27. A PAC valve 24 is attached to thetop of the PAD valve 23. Further, a sub 30 is attached to the top of thePAC valve 24. An upper packer 29 is attached to the top of the PAD valve23 through a section of base pipe 26 which further comprises across-over valve 31.

The third isolation string 32 is stung into the top of the secondisolation string 22. The third isolation string 32 comprises a base pipe36 with a production screen 35 thereon. Within the base pipe 36, thereis a isolation pipe 37 which has an isolation valve 38 therein. Attachedto the tops of the base pipe 36 and isolation pipe 37, there is a PADvalve 33. A sub 40 is attached to the top of the PAD valve on theinterior, and a packer 39 is attached to the exterior of the PAD valve33 through a section of base pipe 36. A production tubing 5 is stunginto the sub 40.

The first isolation string 11 comprises a PAD valve 12 but does notcomprise a PAC valve. The second isolation string 22 comprises both aPAD valve 23 and a PAC valve 24. The third isolation string 32 onlycomprises a PAD valve 33 but does not comprise a PAC valve. Thisproduction system enables sequential grave pack, fracture and isolationof zones 1, 2 and 3. Also, this system enables fluid from productionzones 1 and 2 to be co-mingled and produced through the interior of theproduction tubing, while the fluid from the third production zone isproduced through the annulus around the exterior of the production tube.

The co-mingling of fluids produced by the first and second productionzones is effected as follows: PAD valves 12 and 23 are opened to causethe first and second production zone fluids to flow through theproductions screens 15 and 25 and into the annulus between the basepipes 16 and 26 and the isolation pipes 17 and 27. This co-mingled fluidflows up through the opened PAD valves 12 and 23 to the bottom of thePAC valve 24 is also opened to allow this co-mingled fluid of the firstand second production zones 1 and 2 to flow from the annulus into thecenter of the base pipes 16 and 26 and the sub 30. All fluid produced bythe first and second production zones through the annulus is forced intothe production tube 5 interior through the open PAC valve 24.

Production from the third production zone 3 is effected by opening PADvalve 33. This allows production fluids to flow up through the annulusbetween the base pipe 36 and the isolation pipe 37, up through the PADvalve 33 and into the annulus between the production tube 5 and the wellcasing (not shown).

Referring to FIGS. 3A through 3K, a system is shown wherein a firstisolation string 11 comprises a PAD valve 12 and a PAC valve 13. Thisfirst isolation string 11 is similar to that previously described withreference to FIG. 1. The second isolation string 22 comprises only a PADvalve 23 and is similar to the second isolation string described withreference to FIG. 1. The third isolation string 32 comprises only a PADvalve 33 but no PAC valve and is also similar to the second isolationstring described with reference to FIG. 1. This configuration enablesproduction from zone 1 to pass through the PAC valve into the interiorof the annulus of the production tubing. The fluids from productionzones two and three co-mingle and are produced through the annulus aboutthe exterior of the production tube.

The co-mingling of fluids produced by the second and third productionzones is effected as follows: Opening PAD valves 23 and 33 creates anunimpeded section of the annulus. Fluids produced through PAD valves 23and 33 are co-mingled in the annulus.

Referring to FIGS. 4A through 4N, a system is shown comprising fourisolation strings. The first isolation string 11 comprises a PAD valve12 but no PAC valve. The second isolation string 22 comprises a PADvalve 23 and a PAC valve 24. The third isolation string 32 comprises aPAD valve 33 but does not comprise a PAC valve. Similarly the fourthisolation string 42 comprises a PAD valve 43 but does not comprise a PACvalve. In this particular configuration, production fluids from zonesone and two are co-mingled for production through the PAC valve into theinterior of the production tube 5. The fluids from production zonesthree and four are co-mingled for production through the annulus formedon the outside of the production tube 5.

In this embodiment, the first isolation string 11 is similar to thefirst isolation string shown in FIG. 2. The second isolation string 22is also similar to the second isolation string shown in FIG. 2. Thethird isolation string is also similar to the third isolation stringshown in FIG. 2. However, rather than having a production tubing 5 stunginto the top of the third isolation string, the embodiment shown in FIG.4, comprises a fourth isolation string 42. The fourth isolation stringcomprises a base pipe 46 with a production screen 45 therearound. On theinside of the base pipe 46, there is a isolation pipe 47 which has anisolation valve 48. Attached to the tops of the base pipe 46 and theisolation pipe 47, there is a PAD valve 43. To the interior of the topof the PAD valve 43, there is attached a sub 50. To the exterior of thePAD valve 43, there is attached through a section of base pipe 46, anupper packer 49, wherein the section of base pipe 46 comprises across-over valve 51. A production tubing 5 is stung into the sub 50.

Referring to FIGS. 5A through 5E and 6A through 6E, detailed drawings ofa PAD valve are shown. In FIG. 5, the valve is shown in an open positionand in FIG. 6, the valve is shown in a closed position. In the openposition, the valve enables fluid communication through the annulusbetween the interior and exterior tube of the isolation string.Essentially, these interior and exterior tubes are sections of the basepipe 16 and the isolation pipe 17. The PAD valve comprises a shoulder 52that juts into the annulus between two sealing lands 58. The shoulder 52is separated from each of the sealing lands 58 by relatively largerdiameter troughs 60. The internal diameters of the shoulder 52 and thesealing lands 58 are about the same. A moveable joint 54 is internallyconcentric to the shoulder 52 and the sealing land 58. The moveablejoint 54 has a spanning section 62 and a closure section 64, wherein theoutside diameter of the spanning section 62 is less than the outsidediameter of the closure section 64.

The valve is in a closed position, when the valve is inserted in thewell. The PAD valve is held in the closed position by a shear pin 55. Acertain change in fluid pressure in the annulus will cause the moveablejoint 54 to shift, opening the PAD valve by losing the contact betweenthe joint 54 and the shoulder 52. Since the relative diameters of thespanning section 62 and closure section 64 are different, the annuluspressure acts on the moveable joint 54 to slide the moveable joint 54 toa position where the spanning section 62 is immediately adjacent theshoulder 52. Since the outside diameter of the spanning section 62 isless than the inside diameter of the shoulder 52, fluid flows freelyaround the shoulder 52 and through the PAD valve.

As shown in FIG. 6, in the closed position, the PAD valve restricts flowthrough the annulus. Here, the PAD valve has contact between theshoulder 52 and the moveable joint 54, forming a seal to block fluidflow through the annulus at the PAD valve.

Referring to FIGS. 7A through 7D, there is shown a production tubingassembly 110 according to the present invention. The production tubingassembly 110 is mated in a conventional manner and will only be brieflydescribed herein. Assembly 110 includes production pipe 140 that extendsto the surface and a production screen assembly 112 with PAC valveassembly 108 controlling fluid flow through the screen assembly. In apreferred embodiment production screen assembly 112 is mounted on theexterior of PAC valve assembly 108. PAC valve assembly 108 isinterconnected with production tubing 140 at the uphole end by threadedconnection 138 and seal 136. Similarly on the downhole end 169. PACvalve assembly 108 is interconnected with production tubing extension113 by threaded connection 122 and seal 124. In the views shown, theproduction tubing assembly 110 is disposed in well casing 111 and hasinner tubing 114, with an internal bore 115, extending through the innerbore 146 of the assembly.

The production tubing assembly 110 illustrates a single preferredembodiment of the invention. However, it is contemplated that the PACvalve assembly according to the present invention may have uses otherthan at a production zone and may be mated in combination with a widevariety of elements as understood by a person skilled in the art.Further, while only a single isolation valve assembly is shown, it iscontemplated that a plurality of such valves may be placed within theproduction screen depending on the length of the producing formation andthe amount of redundancy desired. Moreover, although an isolation screenis disclosed in the preferred embodiment, it is contemplated that thescreen may include any of a variety of external or internal filteringmechanisms including but not limited to screens, sintered filters, andslotted liners. Alternatively, the isolation valve assembly may beplaced without any filtering mechanisms.

Referring now more particularly to PAC valve assembly 108, there isshown outer sleeve upper portion 118 joined with an outer sleeve lowerportion 116 by threaded connection 128. For the purpose of clarity inthe drawings, these openings have been shown at a 45° inclination. Outersleeve upper portion 118 includes two relatively large productionopenings 160 and 162 for the flow of fluid from the formation when thevalve is in an open configuration. Outer sleeve upper portion 118 alsoincludes through bores 148 and 150. Disposed within bore 150 is shearpin 151, described further below. The outer sleeve assembly has an outersurface and an internal surface. On the internal surface, the outersleeve upper portion 118 defines a shoulder 188 (FIG. 7C) and an area ofreduced wall thickness extending to threaded connection 128 resulting inan increased internal diameter between shoulder 188 and connection 128.Outer sleeve lower portion 116 further defines internal shoulder 189 andan area of reduced internal wall thickness extending between shoulder189 and threaded connection 122. Adjacent threaded connection 138, outersleeve portion 118 defines an annular groove 176 adapted to receive alocking ring 168.

Disposed within the outer sleeves is inner sleeve 120. Inner sleeve 120includes production openings 156 and 158 which are sized and spaced tocorrespond to production openings 160 and 162, respectively, in theouter sleeve when the valve is in an open configuration. Inner sleeve120 further includes relief bores 154 and 142. On the outer surface ofinner sleeve there is defined a projection defining shoulder 186 and afurther projection 152. Further inner sleeve 120 includes a portion 121having a reduced external wall thickness. Portion 121 extends down holeand slidably engages production pipe extension 113. Adjacent uphole end167, inner sleeve 120 includes an area of reduced external diameter 174defining a shoulder 172.

In the assembled condition shown in FIGS. 7A through 7D, inner sleeve120 is disposed within outer sleeves 116 and 118, and sealed thereto atvarious locations. Specifically, on either side of production openings160 and 162, scals 132 and 134 seal the inner and outer sleeves.Similarly, on either side of shear pin 151, seals 126 and 130 seal theinner sleeve and outer sleeve. The outer sleeves and inner sleevecombine to form a first chamber 155 defined by shoulder 188 of outersleeve 118 and by shoulder 186 of the inner sleeve. A second chamber 143is defined by outer sleeve 116 and inner sleeve 120. A spring member 180is disposed within second chamber 143 and engages production tubing 113at end 182 and inner sleeve 120 at end 184. A lock ring 168 is disposedwithin recess 176 in outer sleeve 118 and retained in the recess byengagement with the exterior of inner sleeve 120. Lock ring 168 includesa shoulder 170 that extends into the interior of the assembly andengages a corresponding external shoulder 172 on inner sleeve 120 toprevent inner sleeve 120 from being advanced in the direction of arrow164 beyond lock ring 168 while it is retained in groove 176.

The PAC valve assembly of the present invention has three configurationsas shown in FIGS. 7 through 9. In a first configuration shown in FIG. 7,the production openings 156 and 158 in inner sleeve 120 are axiallyspaced from production openings 160 and 162 along longitudinal axis 190.Thus, PAC valve assembly 108 is closed and restricts flow through screen112 into the interior of the production tubing. The inner sleeve islocked in the closed configuration by a combination of lock ring 168which prevents movement of inner sleeve 120 up hole in the direction ofarrow 164 to the open configuration. Movement down hole is prevented byshear pin 151 extending through bore 150 in the outer sleeve andengaging an annular recess in the inner sleeve. Therefore, in thisposition the inner sleeve is in a locked closed configuration.

In a second configuration shown in FIGS. 8A through 8D, shear pin 151has been severed and inner sleeve 120 has been axially displaced downhole in relation to the outer sleeve in the direction of arrow 166 untilexternal shoulder 152 on the inner sleeve engages end 153 of outersleeve 116. The production openings of the inner and outer sleevescontinue to be axial displaced to prevent fluid flow there through. Withthe inner sleeve axial displaced down hole, lock ring 168 is disposedadjacent reduced outer diameter portion 174 of inner sleeve 120 suchthat the lock ring may contract to a reduced diameter configuration. Inthe reduced diameter configuration shown in FIG. 8, lock ring 168 maypass over recess 176 in the outer sleeve without engagement therewith.Therefore, in this configuration, inner sleeve is in an unlockedposition.

In a third configuration shown in FIGS. 9A through 9D, inner sleeve 120is axially displaced along longitudinal axis 190 in the direction ofarrow 164 until production openings 156 and 158 of the inner sleeve arein substantial alignment with production openings 160 and 162,respectively, of the outer sleeve. Axial displacement is stopped by theengagement of external shoulder 186 with internal shoulder 188. In thisconfiguration, PAC valve assembly 108 is in an open position.

In the operation of a preferred embodiment, at least one PAC valveaccording to the present invention is mated with production screen 112and, production tubing 113 and 140, to form production assembly 110. Theproduction assembly according to FIG. 7 with the PAC valve in thelocked-closed configuration, is then inserted into casing 111 until itis positioned adjacent a production zone (not shown). When access to theproduction zone is desired, a predetermined pressure differentialbetween the casing annulus 144 and internal annulus 146 is establishedto shift inner sleeve 120 to the unlocked-closed configuration shown inFIG. 8. It will be understood that the amount of pressure differentialrequired to shift inner sleeve 120 is a function of the force of spring180, the resistance to movement between the inner and outer sleeves, andthe shear point of shear pin 151. Thus, once the spring force andresistance to movement have been overcome, the shear pin determines whenthe valve will shift. Therefore, the shifting pressure of the valve maybe set at the surface by inserting shear pins having differentstrengths.

A pressure differential between the inside and outside of the valveresults in a greater amount of pressure being applied on externalshoulder 186 of the inner sleeve than is applied on projection 152 bythe pressure on the outside of the valve. Thus, the internal pressureacts against shoulder 186 of to urge inner sleeve 120 in the directionof arrow 166 to sever shear pin 151 and move projection 152 into contactwith end 153 of outer sleeve 116. It will be understood that relief bore148 allows fluid to escape the chamber formed between projection 152 andend 153 as it contracts. In a similar fashion, relief bore 142 allowsfluid to escape chamber 143 as it contracts during the shiftingoperation. After inner sleeve 120 has been shifted downhole, lock ring168 may contract into the reduced external diameter of inner sleevepositioned adjacent the lock ring. Often, the pressure differential willbe maintained for a short period of time at a pressure greater than thatexpected to cause the down hole shift to ensure that the shift hasoccurred. This is particularly important where more than one valveaccording to the present invention is used since once one valve hasshifted to an open configuration in a subsequent step, a substantialpressure differential is difficult to establish.

The pressure differential is removed, thereby decreasing the forceacting on shoulder 186 tending to move inner sleeve 120 down hole. Oncethis force is reduced or eliminated, spring 180 urges inner sleeve 120into the open configuration shown in FIG. 9. Lock ring 168 is in acontracted state and no longer engages recess 176 such the ring nowslides along the inner surface of the outer sleeve. In a preferredembodiment spring 180 has approximately 300 pounds of force in thecompressed state in FIG. 8. However, varying amounts of force may berequired for different valve configurations. Moreover, alternativesources other than a spring may be used to supply the force for opening.As inner sleeve 120 moves to the open configuration, relief bore 154allows fluid to escape chamber 155 as it is contracted, while reliefbores 148 and 142 allow fluid to enter the connected chambers as theyexpand.

Shown in FIG. 10 is a cross-sectional, diagrammatic view taken alongline A—A of FIG. 9C showing the full assembly.

Although only a single preferred PAC valve embodiment of the inventionhas been shown and described in the foregoing description, numerousvariations and uses of a PAC valve according to the present inventionare contemplated. As examples of such modification, but withoutlimitation, the valve connections to the production tubing may bereversed such that the inner sleeve moves down hole to the openconfiguration. In this configuration, use of a spring 180 may not berequired as the weight of the inner sleeve may be sufficient to move thevalve to the open configuration. Further, the inner sleeve may beconnected to the production tubing and the outer sleeve may be slidabledisposed about the inner sleeve. A further contemplated modification isthe use of an internal mechanism to engage a shifting tool to allowtools to manipulate the valve if necessary. In such a configuration,locking ring 168 may be replaced by a moveable lock that could againlock the valve in the closed configuration. Alternatively, spring 180may be disengageable to prevent automatic reopening of the valve.

Further, use of a PAC valve according to the present invention iscontemplated in many systems. One such system is the ISO system offeredby BJ Services Company U.S.A. (successor to OSCA, Inc.) and described inU.S. Pat. No. 5,609,204; the disclosure therein is hereby incorporatedby reference. A tool shiftable valve disclosed in the above patent is atype of isolation valve and may be utilized within the productionscreens to accomplish the gravel packing operation. Such a valve couldbe closed as the crossover tool string is removed to isolate theformation. The remaining production valves adjacent the productionscreen may be pressure actuated valves according to the presentinvention such that inserting a tool string to open the valves isunnecessary.

FIGS. 11 through 14 illustrate several steps in the construction of anisolation and production system according to an embodiment of thepresent invention.

FIGS. 11A through 11D show a first isolation string 211. The isolationstring comprises a PAD valve 212. At the lower end of the isolationstring 211, there is a lower packer 210 and at the upper end of theisolation string 211 there is an upper packer 219. A base pipe 216 isconnected to the lower packer 210 and has a production screen 215therearound. The isolation string 211 further comprises an isolationvalve 218 on a isolation pipe 217. The PAD valve 212 enables fluidcommunication through the annulus between the isolation pipe 217 and theisolation string 211. The first isolation string 211 also comprises asub 214 attached to the top of the PAD valve 212. Further, in the basepipe section between the PAD valve 212 and the upper packer 219, thereis a cross-over valve 221. This configuration of the first isolationstring 211 enables the first production zone 1 to be fractured, gravelpacked, and isolated through the first isolation string 211. Uponcompletion of these procedures, the isolation valve 218 and PAD valve212 are closed to isolate the production zone 1.

FIGS. 12A through 12I show cross-sectional, side views of two isolationstrings. In particular, a second isolation string 222 is stung inside anisolation string 211. Isolation string 222 comprises a PAD valve 223 anda PAC valve 224. The isolation string 211, shown in this figure, is thesame as the isolation string shown in FIG. 11. After the gravel/pack andisolation function are performed on the first zone with the isolationstring 211, the isolation string 222 is stung into the isolation string211. The second isolation string 222 comprises a base pipe 226 having aproduction screen 225 therearound. The base pipe 226 is stung into thepacker 219 of the first isolation string 211. The second isolationstring 222 also comprises a isolation pipe 227 which is stung into thesub 214 of the first isolation string 211. The isolation pipe 227 alsocomprises an isolation valve 228. At the tops of the base pipe 226 andisolation pipe 227, there is connected a PAD valve 223. A PAC valve 224is connected to the top of the PAD valve 223. Also, a sub 230 isattached to the top of the PAC valve 224. An upper packer 229 is alsoconnected to the exterior portion of the PAD valve 223 through a sectionof base pipe 226 which also comprises a cross-over valve 231.

Referring to FIGS. 13A through 13L, the isolation strings 211 and 222 ofFIG. 12 are shown. However, in this figure, a third isolation string 232is stung into the top of isolation string 222. In this particularconfiguration, isolation strings 211 and 222 produce fluid fromrespective zones 1 and 2 up through the annulus between the isolationstrings and the isolation sleeves until the fluid reaches the PAC valve224. The co-mingled production fluid from production zones 1 and 2 passthrough the PAC valve 224 into the interior of the production string.The production fluids from zone 3 is produced through the isolationstring 232 up through the annulus between the isolation string 232 andthe isolation pipe 237. In the embodiment shown in FIG. 13, the PADvalves 212, 223 and 233 are shown in the closed position so that allthree of the production zones are isolated. Further, the PAC valve 224in isolation string 222 is shown in a closed position.

The third isolation string 232 comprises a base pipe 236 which is stunginto the packer 229 of the second isolation string. The base pipe 236also comprises a production screen 235. Inside the base pipe 236, thereis a isolation pipe 237 which is stung into the sub 230 of the secondisolation string 222. The isolation pipe 237 comprises isolation valve238. A PAD valve 233 is connected to the tops of the base pipe 236 andisolation pipe 237. A sub 234 is connected to the top of the PAD valve233. An upper packer 239 is also connected through a section of basepipe 236 to the PAD valve 233. This section of base pipe also comprisesa cross-over valve 241.

Referring to FIGS. 14A through 14L, the isolation strings 211, 222 and232 of FIG. 13 are shown. In addition to these isolation strings, aproduction tube 240 is stung into the top of isolation string 232. Withthe production tube 240 stung into the system, pressure differential isused to open PAD valves 212, 223, and 233. In addition, the pressuredifferential is used to set PAC valve 224 to an open position. Theopening of these valves enables co-mingled production from zones 1 and 2through the interior of the production tube while production from zone 3is through the annulus on the outside of the production tube 240.

The packers, productions screens, isolations valves, base pipes,isolations pipes, subs, cross-over valves, and seals may beoff-the-shelf components as are well known by persons of skill in theart.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiment has been shown and described and that allchanges and modifications that come within the spirit of the inventionare desired to be protected.

1. A system for completing a well, comprising: a base pipe comprising ahole; at least one packer in mechanical communication with said basepipe; at least one screen in mechanical communication with said basepipe, wherein said at least one screen is proximate the hole in saidbase pipe; an isolation pipe concentric within said base pipe andproximate to the hole in said base pipe, wherein an annulus is definedbetween said base pipe and said isolation pipe; an annular flow valve inmechanical communication with said base pipe and said isolation pipe andadapted to control fluid flow through said annulus above and below saidvalve; and a tool shiftable valve coupled to the isolation pipe.
 2. Thesystem of claim 1, wherein the annular flow valve is a pressureactivated valve.
 3. The system of claim 1, further comprising anadditional valve coupled to the isolation string, the additional valvecomprising a pressure activated valve.
 4. The system of claim 1, furthercomprising a crossover valve in mechanical communication with the basepipe.
 5. The system of claim 1, wherein the tool shiftable valvecomprises a sliding sleeve shiftable between an open position and aclosed position.
 6. The system of claim 5, wherein the system is adaptedto be inserted into a well to allow a gravel pack operation to occurprior to a closure of the sleeve to allow operation of the annular flowvalve through pressurized fluid.
 7. An isolation system, comprising: anisolation pipe comprising a pressure activated valve establishing afirst flow path and coupled to the isolation pipe, and a tool shiftablevalve establishing a second flow path and coupled to the isolation pipeand in communication with the pressure activated valve and beingshiftable by a tool between an opened and closed flow condition.
 8. Thesystem of claim 7, wherein the tool shiftable valve is inserted into awell to allow a gravel pack operation to occur prior to closing the toolshiftable valve to allow operation of the pressure activated valvethrough pressurized fluid.
 9. The system of claim 7, wherein theisolation pipe defines at least one port, and wherein the open positionof the tool shiftable valve allows fluid flow through the port.
 10. Thesystem of claim 7, further comprising: a base pipe; the isolation pipebeing disposed within the base pipe, defining a volume between the basepipe and the isolation pipe; the pressure activated valve comprising avalve adapted to allow flow between the volume formed by the isolationpipe and the base pipe and an internal portion of the isolation pipe.11. The system of claim 7, wherein said pressure activated valvecomprises: an outer sleeve having at least one opening and an innersleeve, the sleeves being movable relative to each other andconfigurable in at least locked-closed, unlocked-closed, and openconfigurations, wherein the inner sleeve covers the at least one openingin the locked-closed and unlocked-closed configurations and the innersleeve does not cover the at least one opening in the openconfiguration; and a pressure area on at least one of the sleeves,wherein pressure acting on the pressure area configures the outer sleeveand inner sleeve between the locked-closed and unlocked-closedconfigurations.
 12. The system of claim 11, further comprising a lockbetween the inner sleeve and the outer sleeve that locks the innersleeve and the outer sleeve in the locked-closed configuration.
 13. Thesystem of claim 11, further comprising a spring member adapted to biasthe inner sleeve relative to the outer sleeve so that the inner sleevedoes not cover the at least one opening of the outer sleeve in the openconfiguration when the lock is released.
 14. The system of claim 11,wherein the inner sleeve comprises at least one opening that isselectably aligned with the at least one opening in the outer sleeve toallow fluid flow therethrough.
 15. The system of claim 14, furthercomprising a production screen, wherein fluid passing through theproduction screen is communicable with the pressure activated valve andthe tool shiftable valve.
 16. The system of claim 15, wherein theproduction screen is wrapped around the outside of the pressureactivated valve and the tool shiftable valve.
 17. A method for isolatinga production zone of a well, comprising: inserting a pipe into the well,the pipe comprising a pressure activated valve and a tool shiftablevalve; shifting the tool shiftable valve with a tool to a closed flowcondition while the tool shiftable valve is disposed in the well; thenopening the pressure activated valve by pressurized fluid acting on thepressure activated valve.
 18. The method of claim 17, wherein openingthe pressure activated valve occurs while the tool shiftable valveremains in the well.
 19. The method of claim 17, further comprisingperforming a gravel pack operation on the well while the tool shiftablevalve is open and the pressure activated valve is closed.
 20. The methodof claim 17, wherein the pipe comprises an isolation string.
 21. Themethod of claim 17, further comprising allowing production fluid to flowthrough the pressure activated valve, the tool shiftable valve, or acombination thereof.
 22. The method of claim 17, wherein shifting thetool shiftable valve comprises using a shifting tool to actuate the toolshiftable valve.
 23. The method of claim 17, wherein the pressureactivated valve comprises an inner sleeve and an outer sleeve having atleast one opening, the sleeves being movable relative to each other inat least two directions and initially secured relative to each other inat least one direction, wherein the opening of the pressure activatedvalve comprises: applying a pressurized fluid to a pressure area on atleast one of the sleeves to cause the sleeves to move relative to eachother in a first direction; reducing pressure to allow the sleeves tomove relative to each other in a second direction; at least partiallyuncovering the at least one opening to allow fluid flow therethrough.24. The method of claim 23, further comprising biasing the sleevesrelative to each other with a spring member and allowing the sleeves tomove relative to each other in the second direction with the springmember after reducing the pressure.
 25. A method for isolating aproduction zone of a well having a perforated casing, comprising:running-in an isolation string into the well, the isolation stringcomprising a pressure activated valve and a tool shiftable valve;setting the isolation string in the casing adjacent the perforations inthe casing; shifting the tool shiftable valve with a shifting tool to ano flow condition; stinging a production string into the isolationstring; and thereafter opening the pressure activated valve.
 26. Themethod of claim 25, wherein the tool shiftable valve is closed duringthe opening of the pressure activated valve.
 27. The method of claim 25,further comprising performing a gravel pack operation on the well whilethe tool shiftable valve is open and the pressure activated valve isclosed.
 28. The method of claim 25, further comprising withdrawing theshifting tool from the well after shifting the tool shiftable valve. 29.The method of claim 25, wherein the isolation string further comprisesan annular flow valve, and further comprising opening the annular flowvalve and allowing fluid flow into the annular flow valve.
 30. Themethod of claim 29, further comprising allowing fluid flow through theannular flow valve while allowing fluid flow through the pressureactivated valve into an internal portion of the isolation pipe.
 31. Themethod of claim 29, further comprising opening the annular flow valvewith a pressurized fluid, actuating the pressure activated valve to anunlocked closed position with the pressurized fluid, reducing thepressure of the pressurized fluid to open the pressure activated valve,and allowing fluid flow through the annular flow valve and the pressureactivated valve.
 32. The method of claim 29, wherein fluid flow throughthe annular flow valve comprises a fluid from a first zone and the fluidflow through the pressure activated valve comprises a fluid from anotherzone.
 33. The method of claim 32, wherein the pressure activated valveis in fluidic contact with a second annular flow valve and the fluidflow through the pressure activated valve and second annular flow valvecomprises the same fluid.
 34. An isolation system for an oil or gaswell, comprising: an isolation pipe; a screen assembly adjacent a wellformation; a tool shiftable valve coupled to the isolation pipe forselectively communicating fluid to and/or from the screen assembly; anda pressure activated valve coupled to the isolation pipe for selectivelycommunicating fluid to and/or from the screen assembly.
 35. Theisolation system of claim 34, wherein the pressure activated valvecomprises a slidable sleeve and the tool shiftable valve is shifted by aremovable tool conveyed along an interior of the isolation pipe.
 36. Theisolation system of claim 35, wherein the pressure activated valve andthe tool shiftable valve are arranged to control fluid in parallel. 37.The isolation system of claim 36, wherein the pressure activated valveis actuated by fluid pressure selected from the group consisting ofisolation pipe pressure, annulus pressure uphole from a packer, annuluspressure adjacent a formation, and any combination thereof.
 38. Theisolation system of claim 37, wherein the pressure activated valve isselected from the group consisting of: a valve for controlling flowthrough an annular space in the isolation system, a valve forcontrolling flow from or to an exterior of the isolation system, and anycombination thereof.
 39. An isolation system, comprising: a base pipe;an isolation pipe disposed within the base pipe; a volume definedbetween the base pipe and the isolation pipe; a pressure activated valvecoupled to the isolation pipe and comprising a valve adapted to allowflow between the volume and an internal portion of the isolation pipe;and a tool shiftable valve coupled to the isolation pipe.
 40. Theisolation system of claim 39, wherein the pressure activated valvecomprises a slidable sleeve and the tool shiftable valve is shifted by aremovable tool conveyed along an interior of the isolation pipe.
 41. Theisolation system of claim 40, further comprising a wherein the pressureactivated valve and the tool shiftable valve are arranged to controlfluid in parallel.
 42. The isolation system of claim 41, furthercomprising a screen assembly externally adjacent the pressure activatedvalve and the tool shiftable valve.
 43. A method for isolating aproduction zone of a well, comprising: inserting a pipe into the wellcomprising a pressure activated valve having a movable sleeve, and atool shiftable valve; shifting the tool shiftable valve closed with atool while the tool shiftable valve is disposed in the well; thereafteropening the pressure activated valve by applying a pressurized fluid toa pressure area on the sleeve to cause the sleeve to move.
 44. A methodfor producing from a well having a perforated casing, comprising:running-in the well a production assembly comprising a pressureactivated valve, an isolation string, a production screen and a toolshiftable valve; setting the production assembly in the casing adjacentthe perforations; shifting the tool shiftable valve with a shiftingtool; stinging a production string into the production assembly; andapplying pressure to the pressure activated valve to open it.
 45. Anisolation system, comprising: an isolation pipe extending below a packerassembly comprising a pressure activated valve establishing a first flowpath and coupled to the isolation pipe, and a mechanically activatedvalve establishing a second flow path and coupled to the isolation pipeand in communication with the pressure activated valve and beingmechanically actuatable by a tool between opened and closed flowconditions.
 46. A method for isolating a production zone of a well,comprising: inserting a pipe into the well comprising a pressureactivated valve and a separate mechanically activated valve; shiftingthe mechanically activated valve with a tool to prevent flow therethrough while the mechanically activating valve is disposed in the well;then opening the pressure activated valve by pressurized fluid acting onthe pressure activated valve.